Proceedings of the 6 th International Mechanical Engineering Conference &

14 th Annual Paper Meet (6IMEC&14APM) 28-29 September 2012, Dhaka, Bangladesh

IMEC&APM-ABS-000

SIZING AND SELECTION OF PRESSURE RELIEF SAFETY

VALVE
Palash Kumar Bhowmik1
1
Assistant Manager, Department of Instrumentation and Communication, Eastern Refinery Limited,
Chittagong, Bangladesh,

ABSTRACT
The purpose of this study is to familiarize with the various parameters involved in the design of a pressure
relief valve and provide a brief introduction for sizing and selection of a pressure relief valve. Once a
condition occurs that causes the pressure in a system or vessel to increase to a dangerous level, the pressure
relief valve may be the only device remaining to prevent a catastrophic failure. Proper sizing, selection,
manufacture, assembly, test, installation and maintenance of a pressure relief valve are all critical to
obtaining maximum protection. This paper proposes better flexibility for sizing and selection of pressure
relief valve. As a case study, pressure relief valve for atmospheric distillation column of crude oil refining
system is studied in this study. It is anticipated that this paper will be very effective to select appropriate
pressure relief safety valve to ensure the safety of pressurized system.

Keywords: Pressure Relief Valve, Maximum Allowable Working Pressure, Proper Sizing and Selection

1. INTRODUCTION examples could be failure of a stop valve to close, control

A pressure relief valve is a safety device designed to
protect a pressurized vessel or system during an
overpressure event. An overpressure event refers to any
condition which would cause pressure in a vessel or
system to increase beyond the specified design pressure
or maximum allowable working pressure (MAWP) [3].
Since pressure relief valves are safety devices, there are
many Codes and Standards written to control their design
and application. Since reliability is directly related to the
complexity of the device, it is important that the design
of the pressure relief valve be as simple as possible. The
pressure relief valve (PSV) must open at a predetermined
set pressure, flow a rated capacity at a specified
overpressure, and close when the system pressure has
returned to a safe level. Pressure relief valves must be
designed with materials compatible with many process
fluids from simple air and water to the most corrosive
media. They must also be designed to operate in a
consistently smooth and stable manner on a variety of
fluids and fluid phases [4].
The first step in applying overpressure protection to a
vessel or system is to determine the set pressure, back
pressure, allowable overpressure, and required relieving
capacity. Set pressure and allowable overpressure can be
determined by reference to the operating pressures of the
system. A more difficult task is determining the required
relieving capacity. The pressure relief valve must relieve
a sufficient amount of fluid to ensure that pressure in the
vessel or system never exceeds the specified
overpressure [5]. This means that all possible sources
and causes of overpressure must be evaluated. Some
system failure, fire, pump failure, uncontrolled chemical
reaction, vessel isolation, and many more. The worst
case combination of these factors is used to determine the
required capacity. Total rated relieving capacity of the
selected must be greater than the required capacity
determined from the worst case system failure analysis.
2. FACTORS RELATED TO PSV SELECTION
The selection of PSV entail following steps [3][4][5]:
2.1 Considering the Process Data/ Parameter
Required flow rate, Set pressure, Allowable
overpressure, Fluid data, gas (molecular weight, Cp/Cv,
compressibility factor), liquid (density, viscosity), steam
(temperature), Service conditions (back pressure,
temperature) Environmental requirements (corrosion),
Flange standards
2.2 Orifice Selection
Using capacity tables for known fluids (air/
steam/water) and given overpressure, select the orifice
size corresponding to minimum required flow rate.
2.3 Valve Selection
Using the manufacturer’s valve capacity table or
relevant orifice selection chart, select the model number
that is suitable for pressure/temperature rating.
2.4 Valve Characteristics
Manufacturer’s valve selection table shows inlet and
outlet sizes and flange ratings, valve dimensions and
weights.

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2.5 Options and Accessories
Options and accessories like rapture disk, rapture pin,
pilot operated safety relief valve must be separately
specified. In this study emphasis is given to Safety Relief
Valve Sizing for Vaporizing Liquids (Fire condition).
Select the code and standard
Select the fluid
Determine the total wetted surface area
Determine the total heat absorption
Determine the fluid mass flow
converted to gas from the liquid
Wetted Surface Area Awet in square feet:
(l) Sphere:
Awet = ( Es )( D ) (1)
(2) Horizontal Cylinder with flat ends:
Awet =[(D)(B) / 180] (L+D/2) - (D/2 -E)sin(B) (2)
(3)Horizontal Cylinder with spherical ends:
Awet = ( D ) { E + [(L - D) (B) ] / 180 } (3)
(4)Vertical Cylinder with flat ends:
If E < L then: Awet = ( D ) ( D/4 + E ) (4)
If E = L then: Awet = ( D ) ( D/2 + E ) (5)
(5)Vertical Cylinder with spherical ends:
Awet = ( E ) ( D ) (6)
B = cos-1 [ 1 - ( 2 ) ( E ) / ( D ) ] (7)

Determine the minimum relieving area where,

Consider all correction factors
Calculate the required orifice area
Select the next higher orifice size
According to the Pr. and T select the
valve model
Valve nozzles size dimensions selection
Awet is the total wetted area in square feet
B= Effective liquid level angle, degrees.
L = Vessel end-to-end length, feet.
E = Effective liquid level, feet
Es = Effective spherical liquid level, feet,
E1 = Initial liquid level, feet.
D = Vessel diameter, feet.
K = Effective total height of liquid surface, feet.
K1 = Total height of liquid surface, feet.
H = Vessel elevation, feet.
F = Liquid depth in vessel, feet.

Valve accessories selection

Fig 1. Flow chart of PSV selection & sizing

3. SIZING PSV FOR VAPORIZING LIQUIDS

CONSIDERING FIRE CONDITIONS
The following method may be used for calculating the
required orifice area for pressure relief valves on vessels
containing liquids that are exposed to fire with reference
API Recommended Practice 520.
3.1 Determine the Total Wetted Surface Area
The following formulae are used to determine the
wetted surface area of a vessel. To accomplice this use
the logic stated in Fig. 3 which is derived from API code.
Table 1: Environmental Factor for pressure vessel [1]

Equipment Type Factor F

Bare Vessel 1
Insulated Vessel : 4 0.3
2 0.15
1 0.075
0.67 0.05
0.50 0.0376
0.40 0.03
0.33 0.026
Water application facilities, on 1.0
bare vessels
Depressurizing and emptying 1.0
Fig 2. Fire Sizing Vessel (Tank) Selection Diagram [3]
facilities

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 (4) Orifice area calculation for Air (Nm3/h)
A= V*√ T] \ [1125*K*P1*Kb] (15)
Where,
A = Orifice area required, cm2
W = Required capacity, Kg/hr
V = Required capacity, Nm3/hr
VL = Required capacity, m3/hr
G = density of a gas to air or liquid compared to water
M = Molecular weight
Z = Compressibility factor. If unknown, use Z=1
T = Relieving temperature, absolute
C = Gas constant,
Specific heat ratio, k = Cp/Cv.
k =
If unknown, use k = 1.001,
K = Flow factor. For gas and steam use K = 0.975
K1 = Certified flow factor, liquid K1 = 0.701
K2 = Flow factor API 520, liquid K2 = 0.62
P1 = Relieving pr. (abs) P1 = set pr. + over pr.+ 1.013
P = Set pressure
Pb = Back pressure
Kb = Back pressure correction factor,
KSH = Correction factor for Superheated steam.
Kw = Back pressure correction factor for liquids,
Fig 3. Logic Diagram for Effective Liquid Level [3] Kv = Viscosity correction factor (For water, use Kv = 1)
For valves with uncertified flow factor, (For 10% o/v
3.2 Determine the Total Heat Absorption Kp = pr. Kp = 0.6. For 15% o/v Kp = 0.8. For 25% o/v pr.
The following formulae are used to determine the total Kp=1)
heat absorption: KN = Correction factor for Napier equation,
(l) When prompt fire-fighting efforts and adequate
drainage exist:
3.5 Calculate the Correction Factors [1] [2] [3]
Q = 21,000 F (Awet) 0.82 (8)
The correction factors for proper sizing and selection of
(2) When prompt fire-fighting efforts and adequate pressure relief safety valve can be ensured by following
drainage do not exist: the below logic diagram.
Q = 21,000 F (Awet) 0.82 (9)
Q = 34,500 F (Awet) 0.82 (10) Start
Where, Q is the total heat absorption, BTU/hr
3.3 Determine the Rate of Vapor from the Liquid Compressible Fluid Incompressible Fluid
Fluid
W = Q / Hvap (11)
Compressibilit
Where, W is the mass flow, lbs/hr and Hvap is the latent
heat of vaporization, BTU/lb. Back Variable Pb
Balanced
Pr.
3.4 Calculate the Minimum Required Relieving Constant Pb bellows valve
Area or Pb = 0 Pb (gauge) = Max. Pb/set pr.
The valves are normally sized by calculating the Pb (gauge) = Max.Pb/
minimum area required or by selecting an orifice size Y set pr.
Pb abs /P1
from the manufacturer’s valve capacity table. ≤ 0.55 Pb (gauge) >
10% set Pr. Kw from Fig. 7
(l) Orifice Area Calculation for Gas or Steam (Kg/h) Kb=1
N N
A= [1.3164* W*√ ( T* Z )]/[C*K* P1* Kb * √ M] (12) Y
Go to Fig. 5
Balanced Conventional
(2) Orifice Area Calculation for Steam (Kg/h)
bellows valve valve selection
A= W / [52.5*K* P1 * Kb *KSH*KN] (13)
3
(3) Orifice Area Calculation for Liquid (m /h) Kb from Fig. 6
A= [0.196* VL*√ G]/ [K1*Kw*Kv*√ (1.1*P-Pb )] (14) Fig 4. Logic diagram for Pb correction factor

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 Renold Number

Fig 8. Viscosity correction factor, KV

Fig 5. Back pressure correction factor, Kb (constant
For viscous fluid the capacity correction factor is
back pr., valve without bellows) gas & steam
accomplice by the following logic diagram expressed in
Fig.9.

Start

Calculate the orifice area, A

considering Kv = 1

Select the next

orifice area, A'

Determine the Reynolds Number

R = 3100 * VL* G /( µ √ A´ )

Enter Fig. 4 to fine Kv

Re-calculate the required orifice

area, A using new Kv
Fig 6. Back pressure correction factor, Kb (balanced
bellows valve only) gas & steam at 10% overpressure
Calculate new A'

If A< A'

Sizing Correct Select next larger

orifice size

Fig 9. Capacity Correction for Viscous Fluid

Table 2: PSV orifice Area according to API 526 in cm2

Orifice
D E F G H J K L
Area
Area 18.
0.71 1.26 1.98 3.24 5.06 8.3 11.86
(cm2) 41
Orifice
M N P Q R T V* W*
Area
Area
Fig 7. Back pressure correction factor, KW (variable back (cm2) 23.2 28 41.2 71.2 103 168 271 406
pr., balanced bellows valve on liquid service only)

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3.6 Select the Orifice Size and Valve Model
After calculating required discharge area, A then
select the next larger orifice size from Table: 2. Using the
manufacture valve orifice selection table and valve
operating curve with respect to the relieving temperature
select the valve model suitable for a set pressure.
Considering the back pressure select the conventional or
balance bellows valve type. For air service, specify lift
lever if required by applicable code. For multiple valve
selection use 16% accumulation instead of 10%
accumulation. Other features like rapture disk, rapture
pin, pilot operated safety relief valve, and multiple valve
type or valve accumulation value may be selected
considering specific service condition.
4. SELECTION OF PSV FOR ATMOSPHERIC
DISTILLATION COLUMN OF CRUDE OIL
REFINING PROCESS (CASE STUDY)
The sizing and selection of pressure relief safety valve
for atmospheric distillation column of crude oil refining
process of Eastern Refinery Ltd., Chittagong is
completed in this paper as a case study.
4.1 Data for Sizing and Selection of PSV
The design and operating data for safety valve of
existing atmospheric distillation column of Eastern
Refinery Ltd., Chittagong are as follows-
Reliving fluid = Gas
W = 50000 kg/hr, Required reliving capacity(each valve)
M= 94 kg/ kMole, Molecular weight
Z= 1, Compressibility factor (If unknown, use Z=1)
T= 473K, Relieving temperature (absolute)
C= 344, Gas constant (specific heat ratio, k =1.27)
K= 0.975, Flow factor (for gas & steam use K = 0.975)
P= 3.2 Bar, Set pressure
Pb= 0, Back pressure
Use three PSV for the application.
4.2 Calculation for Sizing and Selection of PSV
Relieving pressure (absolute),
P1 = set pressure + over pressure + Atmospheric pressure
P1 = 3.2+ (3.2×16%) +1.013 Bar
= 4.725 Bar
The required number of PSV for above purpose is 3.
So, over pressure= 16% of set Pr.
From Fig.4, Back pressure correction factor
Kb= 1,
Orifice area for Gas or steam (Kg/h)
A= [1.3164× W×√ ( T×Z )] / [C×K× P1× Kb×√ M]
= 93.16647 cm2
The next higher orifice size from Table:2
A' = 103 cm2
Now, the modified valve flow rate = (A' /A) ×W
= 55277.4 kg/hr
Using the Serasin RSBD valve manufacturer we
select the valve model for R orifice, orifice size 103 cm2,
reliving temperature 473K and set pressure 3.2 bar is as
© IMEC &APM 2012
follows-
Valve model: P68R1 6RB 150lbs
Dimensions: A = 239.7
B = 241.3
Inlet DN = 6" ×150lbs
Outlet DN = 8" × 150lbs
Weight = 215kg
Conventional type (since there is no back pressure)
So valve model determined as P68R1 330
5. RESULT AND DISCUSSION
Considering all the design and operating parameter,
the calculated pressure relief valve with associated
features for atmospheric distillation column for crude oil
refining process of Eastern Refinery Limited, Chittagong
is found same to the original existing pressure safety
valve. As the calculation and selection procedure is
performed according to the prescribed method of this
paper which is a very general and not for specific design
case. As the guideline of this paper is simple and accurate
so the author wish that it will help the young
professionals to size and select the appropriate pressure
relief safety valve.
6. CONCLUSION
In general, the reliability of a system is related to the
complexity of that system. To ensure the reliability with
using simple course of action this paper may help the
professional to size and select a proper pressure relief
safety valve to ensure safety and uninterrupted operation
of their process plant in a systematic and economical
way. Though the final design must always be guaranteed
by the manufacturer, but this study will greatly reduce
the amount of up front engineering hours. The paper will
be a useful training tool for young engineers or a resource
for professionals.
ACKNOWLEDGEMENT
The authors would like to thank Mr. Sharafat Ali,
Assistant General Manager, Department of
Instrumentation & Communication, Eastern Refinery
Limited, Bangladesh for his valuable guidelines and
supervision to complete the task. Cordial thanks also to
Md. Ali Zulquarnain, Member, Planning, Bangladesh
Atomic Energy Commission (BAEC) for his valuable
review and comments.
REFERENCES
1. API Recommendation Practice 520 & API RP 520.
2. Serasin RSBD, Safety Relief Valve, Startflow and
Series 9, SRSBD 2-0605
3. CROSBY, Pressure Relief Valve Engineering
Handbook, Practical Document No. TP-V300
4. KLM Technology Group, Pressure Relief Valve
Sizing and Selection (Engineering Guideline)
5. Selection and Sizing of Pressure Relief Valve,
Randall W. Whitesides P.E.
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